Limiting peak electrical power drawn by mining excavators

• US 8,536,814 B2
• Filed: 05/08/2012
• Issued: 09/17/2013
• Est. Priority Date: 05/15/2009
• Status: Active Grant

• Current Assignee: Innomotics GmbH
• Original Assignee: Caterpillar Incorporated, Siemens AG, Siemens Industry Incorporated (Siemens AG)
• Inventors: Mazumdar, Joy, Kllner, Walter, Holweck, Andreas, Onsager, Michael G., Pittius, Ekkehard
• Primary Examiner(s): Masih, Karen
• Application Number:
  US13/466,802
• Publication Number:
  US 20120257424A1
• Time in Patent Office: 497 Days
• Field of Search: 318/376, 318/440, 318/434, 318/433, 318/432, 320/167, 361/502, 363/34
• US Class Current: 318/440
• CPC Class Codes: E02F 9/207 of the type electric propulsion units, e.g. electric motors or generators
• CPC Class Codes: E02F 9/2091 Control of energy storage means for electrical energy, e.g. battery or capacitors energy recovery arrangements in hydraulic or pneumatic drives E02F9/2217
• CPC Class Codes: H02P 5/74 controlling two or more ac dynamo-electric motors H02P5/46, H02P5/60 take precedence

Abstract

The maximum electrical power drawn from an electrical power source by a mining excavator comprising electric motors is reduced by supplying supplementary electrical power from an electrical energy storage unit. The input electrical power drawn by the mining excavator is cyclic. An upper limit is set for the electrical power drawn from the electrical power source. When the input electrical power drawn by the mining excavator exceeds the upper limit, electrical power is supplied by the electrical energy storage unit, such as an ultracapacitor bank. The ultracapacitor bank may be charged by the electrical power source during off-peak intervals. Electrical power generated by electrical motors operating in a regeneration interval may also be recaptured and stored in the electrical energy storage unit.

Claims

1. A method for transferring electrical power, the method comprising:

receiving a first electrical power regenerated from an electrical motor operating during a regeneration interval;

converting the first electrical power to a direct-current electrical power;

feeding a direct-current link with the direct-current electrical power; and

transferring a second electrical power from the direct-current link to an electrical power grid.

2. The method of claim 1, wherein transferring a second electrical power from the direct-current link to an electrical power grid comprises:

converting the second electrical power to an alternating-current electrical power; and

transferring the alternating-current electrical power to the electrical power grid.

3. The method of claim 2, wherein converting the second electrical power to an alternating-current electrical power is performed by an active front end.

4. The method of claim 1, wherein the electrical power grid comprises a public utility electrical power grid.

5. A method for transferring electrical power, the method comprising:

receiving a first electrical power regenerated from an electrical motor operating during a regeneration interval;

converting the first electrical power to a direct-current electrical power;

feeding a direct-current link with the direct-current electrical power;

determining a charge of an electrical energy storage unit;

upon determining that the charge is less than a user-defined charge limit, transferring a second electrical power from the direct-current link to the electrical energy storage unit; and

upon determining that the charge is greater than or equal to the user-defined charge limit, transferring the second electrical power from the direct-current link to an electrical power grid.

6. The method of claim 5, wherein transferring the second electrical power from the direct-current link to an electrical power grid comprises:

converting the second electrical power to an alternating-current electrical power; and

transferring the alternating-current electrical power to the electrical power grid.

7. The method of claim 6, wherein converting the second electrical power to an alternating-current electrical power is performed by an active front end.

8. The method of claim 5, wherein the electrical energy storage unit comprises an ultracapacitor.

9. The method of claim 5, wherein the electrical power grid comprises a public utility electrical power grid.

10. A system for transferring electrical power, the system comprising:

an electrical power conversion system configured to;

receive a first electrical power regenerated from an electrical motor operating during a regeneration interval; and

convert the first electrical power to a direct-current electrical power;

a direct-current link operatively coupled to the electrical power conversion system, wherein the direct-current link is configured to receive the direct-current electrical power; and

an active front end operatively coupled to the direct-current link, wherein the active front end is configured to;

receive a second electrical power from the direct-current link;

convert the second electrical power to an alternating-current electrical power; and

transfer the alternating-current electrical power to an electrical power grid.

11. The system of claim 10, further comprising a controller, wherein:

the controller is operatively coupled to the direct-current link;

the controller is operatively coupled to the active front end; and

the controller is configured to;

determine a third electrical power drawn by an application load from the direct-current link; and

upon determining that the third electrical power is less than a user-defined electrical power limit, transfer the second electrical power to the active front end.

12. The system of claim 10, wherein the electrical power grid comprises a public utility electrical power grid.

13. A system for transferring electrical power, the system comprising:

an electrical power conversion system configured to;

receive a first electrical power regenerated from an electrical motor operating during a regeneration interval; and

convert the first electrical power to a direct-current electrical power;

a direct-current link operatively coupled to the electrical power conversion system, wherein the direct-current link is configured to receive the direct-current electrical power;

an electrical energy storage unit operatively coupled to the direct-current link, wherein the electrical energy storage unit is configured to receive a second electrical power from the direct-current link; and

an active front end operatively coupled to the direct-current link, wherein the active front end is configured to;

receive a third electrical power from the direct-current link;

convert the third electrical power to an alternating-current electrical power; and

transfer the alternating-current electrical power to an electrical power grid.

14. The system of claim 13, further comprising a controller, wherein:

the controller is operatively coupled to the direct-current link;

the controller is operatively coupled to the electrical energy storage unit;

the controller is operatively coupled to the active front end; and

the controller is configured to;

determine a charge of the electrical energy storage unit;

upon determining that the charge is less than a user-defined charge limit, transfer the second electrical power from the direct-current link to the electrical energy storage unit; and

upon determining that the charge is greater than or equal to the user-defined charge limit, transfer the third electrical power from the direct-current link to the active front end.

15. The system of claim 13, further comprising a controller, wherein:

the controller is operatively coupled to the direct-current link;

the controller is operatively coupled to the electrical energy storage unit;

the controller is operatively coupled to the active front end; and

the controller is configured to;

determine a fourth electrical power drawn by an application load from the direct-current link; and

upon determining that the fourth electrical power is less than a user-defined power limit;

determine a charge of the electrical energy storage unit;

upon determining that the charge is less than a user-defined charge limit, transfer the second electrical power from the direct-current link to the electrical energy storage unit; and

upon determining that the charge is greater than or equal to the user-defined charge limit, transfer the third electrical power from the direct-current link to the active front end.

16. The system of claim 13, wherein the electrical energy storage unit comprises an ultracapacitor.

17. The system of claim 13, wherein the electrical power grid comprises a public utility electrical power grid.